US8618698B2 - System and method for controlling a M2LC system - Google Patents

System and method for controlling a M2LC system Download PDF

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US8618698B2
US8618698B2 US13/228,483 US201113228483A US8618698B2 US 8618698 B2 US8618698 B2 US 8618698B2 US 201113228483 A US201113228483 A US 201113228483A US 8618698 B2 US8618698 B2 US 8618698B2
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m2lc
output phase
multilevel converter
modular multilevel
converter system
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US20120068555A1 (en
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Marc Francis AIELLO
Dustin Matthew Kramer
Kenneth Stephen Berton
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Benshaw Inc
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Curtiss Wright Electro Mechanical Corp
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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M7/00—Conversion of ac power input into dc power output; Conversion of dc power input into ac power output
    • H02M7/42—Conversion of dc power input into ac power output without possibility of reversal
    • H02M7/44—Conversion of dc power input into ac power output without possibility of reversal by static converters
    • H02M7/48—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
    • H02M7/53—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal
    • H02M7/537—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only, e.g. single switched pulse inverters
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M7/00—Conversion of ac power input into dc power output; Conversion of dc power input into ac power output
    • H02M7/42—Conversion of dc power input into ac power output without possibility of reversal
    • H02M7/44—Conversion of dc power input into ac power output without possibility of reversal by static converters
    • H02M7/48—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
    • H02M7/483—Converters with outputs that each can have more than two voltages levels
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J1/00—Circuit arrangements for dc mains or dc distribution networks
    • H02J1/10—Parallel operation of dc sources
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M1/00—Details of apparatus for conversion
    • H02M1/0095—Hybrid converter topologies, e.g. NPC mixed with flying capacitor, thyristor converter mixed with MMC or charge pump mixed with buck
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M7/00—Conversion of ac power input into dc power output; Conversion of dc power input into ac power output
    • H02M7/42—Conversion of dc power input into ac power output without possibility of reversal
    • H02M7/44—Conversion of dc power input into ac power output without possibility of reversal by static converters
    • H02M7/48—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M7/00—Conversion of ac power input into dc power output; Conversion of dc power input into ac power output
    • H02M7/42—Conversion of dc power input into ac power output without possibility of reversal
    • H02M7/44—Conversion of dc power input into ac power output without possibility of reversal by static converters
    • H02M7/48—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
    • H02M7/483—Converters with outputs that each can have more than two voltages levels
    • H02M7/4833—Capacitor voltage balancing
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M7/00—Conversion of ac power input into dc power output; Conversion of dc power input into ac power output
    • H02M7/42—Conversion of dc power input into ac power output without possibility of reversal
    • H02M7/44—Conversion of dc power input into ac power output without possibility of reversal by static converters
    • H02M7/48—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
    • H02M7/483—Converters with outputs that each can have more than two voltages levels
    • H02M7/4835—Converters with outputs that each can have more than two voltages levels comprising two or more cells, each including a switchable capacitor, the capacitors having a nominal charge voltage which corresponds to a given fraction of the input voltage, and the capacitors being selectively connected in series to determine the instantaneous output voltage
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M1/00—Details of apparatus for conversion
    • H02M1/0003—Details of control, feedback or regulation circuits
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M1/00—Details of apparatus for conversion
    • H02M1/32—Means for protecting converters other than automatic disconnection
    • H02M1/325—Means for protecting converters other than automatic disconnection with means for allowing continuous operation despite a fault, i.e. fault tolerant converters

Definitions

  • This application discloses an invention which is related, generally and in various embodiments, to a system and method for controlling a Modular Multilevel Converter (M2LC) system.
  • M2LC Modular Multilevel Converter
  • FIG. 1 illustrates a two-level configuration of an M2LC cell having two terminals
  • FIG. 2 illustrates a three-level configuration of an M2LC cell having two terminals
  • FIG. 3 illustrates a M2LC system.
  • the M2LC cell includes two switching devices, two diodes, a capacitor and two terminals.
  • the two switching devices can be controlled such that one of two different potentials (e.g., zero volts or V cap ) may be present across the two terminals.
  • the M2LC cell includes four switching devices, four diodes, two capacitors and two terminals. With the configuration shown in FIG. 2 , the four switching devices can be controlled such that one of three different potentials (e.g., zero volts, V cap , or 2V cap ) may be present across the two terminals.
  • all of the topologies may be defined as two-terminal subsystems or cells with internal capacitor energy storage(s) which are capable of producing various levels of voltages between the two terminals depending on the state of the switching devices.
  • the M2LC system may be configured as a three-phase bridge which includes a plurality of M2LC cells (subsystems), where the M2LC cells are arranged as three output phase modules.
  • M2LC systems may be configured differently than shown in FIG. 3 .
  • other M2LC systems may be configured as two output phase modules.
  • each output phase module includes a plurality of series-connected M2LC cells, and each output phase module is further arranged into a positive arm (or valve) and a negative arm (or valve), where each arm (or valve) can be separated by an inductive filter.
  • Each output phase module may be considered to be a pole.
  • the respective inductive filters are utilized in the M2LC topology when more than one pole of the M2LC system is paralleled on one common DC bus.
  • the inductive filters operate to reduce currents produced by the switching in the arms of the M2LC system.
  • the spectral content of the arm currents can be shown to be a function of the switch functions and the output current of the pole.
  • Some embodiments of the M2LC system employ inductive filters which have relatively large inductance values along with an active pole current controller to ultimately control the quality of the arm currents.
  • each M2LC cell also includes a local controller, and each local controller may be communicably connected to a higher level controller (e.g., a hub controller) of the M2LC system.
  • a higher level controller e.g., a hub controller
  • the M2LC topology possesses the advantages of the Cascaded H Bridge (CCH) topology in that it is modular and capable of high operational availability due to the ability to add one or more redundant cells in each arm. Additionally, the M2LC topology can be applied in common bus configurations. In contrast to M2LC, CCH requires the utilization of a multi-winding transformer which contains individual secondary windings which supply input energy to the cells.
  • CCH Cascaded H Bridge
  • the M2LC cells are not independently supplied from isolated voltage sources or secondary windings.
  • the amount of energy output at one of the two terminals depends on the amount of energy input at the other one of the two terminals and to some extent the ability of the cell to store and release energy. This can cause a problem in controlling the DC link voltages in these cells during pre-charge of the power circuit or during abnormal operation when one or more of the cells needs to be bypassed or made inactive.
  • these methods duplicate the shorting of cells and placing a “1” state like wise in the other output phase module(s) (e.g., as required in the poles of B and C phase) so that the output line to line voltage is not affected by harmonics.
  • M2LC systems Additional issues with known M2LC systems include acceptable operation at low output frequencies and the ability to develop sufficient DC output current. These performance features can be very important when the M2LC system is utilized for AC motor control, particularly for high starting torque applications. Since there is no external voltage source supplying the cell such as with the CCH topology, the output fundamental current should be fully maintained in the cells and their energy storage devices. Since it is well known that the impedance of a capacitor or electrical condenser monotonically increases with each decrease in output frequency, the resulting peak ripple voltage in the M2LC cell can exceed damaging levels at low frequencies under even rated current condition. Likewise, the ability of the M2LC system to produce DC current, which is important in starting brushless or synchronous motor applications, is difficult to attain with the M2LC system using known control techniques.
  • FIG. 1 illustrates a two-level configuration of an M2LC cell having two terminals
  • FIG. 2 illustrates a three-level configuration of an M2LC cell having two terminals
  • FIG. 3 illustrates a M2LC system having a plurality of M2LC cells
  • FIG. 4 illustrates various embodiments of a M2LC system having a plurality of M2LC subsystems
  • FIG. 5 illustrates a high level representation of a system control module of the M2LC system of FIG. 4 according to various embodiments
  • FIG. 6 illustrates a high level representation of a system control module of the M2LC system of FIG. 4 according to other embodiments
  • FIG. 7 illustrates a high level representation of a system control module of the M2LC system of FIG. 4 according to yet other embodiments
  • FIG. 8 illustrates various embodiments of a M2LC system which includes a dual IGBT bypass connected to a three-level M2LC cell of the M2LC system;
  • FIG. 9 illustrates a simplified representation of a pole of the M2LC system of FIG. 4 ;
  • FIG. 10 illustrates the pole impedance and the capacitor voltage response of a M2LC pole of the M2LC system of FIG. 4 when an inductive filter of the M2LC system has a first inductance value
  • FIG. 11 illustrates the pole impedance and the capacitor voltage response of a M2LC pole of the M2LC system of FIG. 4 when an inductive filter of the M2LC system has a second inductance value.
  • FIG. 4 illustrates various embodiments of a M2LC system 10 having a plurality of M2LC subsystems 12 .
  • the M2LC system 10 is similar to the M2LC system of FIG. 3 in that the M2LC subsystems 12 are arranged as output phase modules, with each output phase module further arranged into a positive arm 14 and a negative arm 16 .
  • an output phase module of the M2LC system 10 of FIG. 3 defines a total value of inductance which is much smaller than the inductance of an output module of the M2LC system of FIG. 3 .
  • the total value of the inductance for an output phase module of the M2LC system 10 of FIG. 4 is approximately 40-50 times smaller than the inductance of an output phase module of the M2LC system of FIG. 3 .
  • the “smaller” deterministically defined total value of inductance allows a system control module (SCM) to control the M2LC system 10 in a manner which auto balances the capacitor voltages of the respective M2LC subsystems 12 and minimizes the fundamental capacitor voltage ripple.
  • SCM system control module
  • system control module 4 as residing at the respective M2LC subsystems 12 (only one SCM is shown for purposes of clarity), it will be appreciated that according to other embodiments, the system control module may reside at a higher level controller (e.g., the hub controller) of the M2LC system 10 . Various embodiments of the system control module will be described in more detail hereinbelow.
  • the total value of inductance defined by a given output phase module of the M2LC system 10 may be realized in any number of different ways.
  • the total value of inductance may be realized by including a deterministically sized inductive filter 18 connected between the positive and negative arms 14 , 16 as shown in FIG. 4 .
  • the inductive filter 18 is shown in FIG. 4 as having two inductors connected between the positive and negative arms 14 , 16 of an output phase module, it will be appreciated that the inductive filter 18 may have any number of inductors (e.g., one, two, three, four, etc.) connected between the positive and negative arms 14 , 16 of an output phase module. Regardless of whether one, two, three, four, etc.
  • inductors are connected between the positive and negative arms 14 , 16 of an output phase module, the individual inductors are deterministically sized so that the total inductance of the output phase module equals the desired total value of inductance so that the system control module (SCM) can control the M2LC system 10 in a manner which auto balances the capacitor voltages of the respective M2LC subsystems 12 and minimizes the fundamental capacitor voltage ripple.
  • SCM system control module
  • the total value of inductance may be realized by including one or more smaller deterministically sized inductors distributed amongst one or more of the M2LC subsystems 12 of the output phase module. This arrangement may be done in lieu of or in conjunction with an inductive filter 18 being connected between the positive and negative arms 14 , 16 .
  • the one or more smaller deterministically sized inductors may be connected to output terminals of a plurality of the M2LC subsystems 12 of the output phase module.
  • the total inductance of the output phase module sums to the desired value of inductance so that the system control module (SCM) can control the M2LC system 10 in a manner which auto balances the capacitor voltages of the respective M2LC subsystems 12 and minimizes the fundamental capacitor voltage ripple.
  • SCM system control module
  • the desired value of inductance can be realized regardless of the number of inductors utilized, whether the inductors are connected between the positive and negative arms 14 , 16 , whether the inductors are distributed amongst the M2LC subsystems 12 , whether the inductors are connected to output terminals of a plurality of the M2LC subsystems 12 , etc.
  • the total value of inductance may be realized solely by the parasitic inductance of the output phase module.
  • the total value of inductance has been described in the context of the output phase module/pole, it will be appreciated that the total inductance in each arm may also be deterministically realized by utilizing one or more of the above-described embodiments.
  • FIG. 5 illustrates a high level representation of the system control module 20 of the M2LC system 10 according to various embodiments. For purposes of clarity, only a portion of the M2LC system is shown in FIG. 5 .
  • the system control module 20 (or its functional equivalent) may be utilized to control the M2LC system 10 in a manner which minimizes the voltage balance and fundamental output frequency ripple voltage shortcomings associated with other M2LC systems if the defined total value of inductance of each output phase module is sized appropriately with the effective arm capacitance to make (1) the impedance of each output phase module low enough to allow a low rate of switch “reassignment” of the switch functions (described in more detail hereinbelow) to auto balance the capacitor voltages of the M2LC subsystems 12 and (2) the resonant frequency high enough relative to the switching frequency to allow phase control of the switching devices to allow a certain degree of two-level operation (described in more detail hereinbelow) to cancel a majority of the fundamental current component in the capacitors of the M2LC subsystems 12
  • this two-level operation implies that the M2LC subsytems 12 in each arm spend a sufficient time in the zero voltage state and thus connected to either the plus (+) bus or the minus ( ⁇ ) bus long enough so that the fundamental arm current cancels with the other phases.
  • the resonate frequency of the pole formed by pole inductance and series arm capacitance (See FIG. 9 ) must be greater than the switching frequency of the switch functions.
  • the system control module 20 may be implemented in hardware, firmware, software and combinations thereof, and may reside at the higher level controller (the hub controller) of the M2LC system. According to other embodiments, the system control module 20 may reside at the local controllers (See, e.g., controller 56 in FIG. 8 ) of the respective M2LC subsystems 12 .
  • the software may utilize any suitable computer language (e.g., C, C++, Java, JavaScript, Visual Basic, VBScript, Delphi) and may be embodied permanently or temporarily in any type of machine, component, physical or virtual equipment, storage medium, or propagated signal capable of delivering instructions to a device.
  • system control module 20 is embodied as software (e.g., software application, computer program)
  • the software may be stored on a computer-readable medium (e.g., disk, device, and/or propagated signal) such that when a computer reads the medium, the functions described herein are performed.
  • a computer-readable medium e.g., disk, device, and/or propagated signal
  • the functionality of the control system module 20 is an adaptation of a traditional triangle PWM modulator used for a multilevel system such as M2LC or CCH.
  • the high level representation shown in FIG. 5 illustrates performance features of switch “reassignment” and relative two-level operation.
  • the control system module 20 includes the functionality of a subsystem sequence generator which produces “n” distinct existence functions for the “n” M2LC subsystems 12 which comprise either the positive arm 14 or negative arm 16 of a given output phase module.
  • the subsystem sequence generator may be controlled by the variable “rate” which defines the complete period at which each function repeats.
  • the functionality of the triangle wave generator which is a set of triangle waveforms which are normally spaced by the value of 2 ⁇ /n, utilizes an additional variable “omega” which can be varied between 0 and 1.
  • the spacing between the triangle waveforms may be represented by the value of “(2 ⁇ /n) ⁇ (omega)”.
  • Omega may be controlled to low values (for instance 0.1) for applications in which the M2LC system 10 must produce high currents and low output frequencies.
  • omega controlled to such a value, the desired effect of switch “reassignment” to auto balance the capacitor voltages of the M2LC subsystems 12 still works, the arms 16 , 18 can be respectively connected to the plus (+) bus or the minus ( ⁇ ) bus for the required time to cancel the fundamental current component in the capacitors (assuming the required time is longer than the period of the pole resonant frequency), and at low modulation levels, the multilevel line to line voltage quality is as good as or better than is the case when omega is set equal to 1. Operating at this relative two-level mode also allows the M2LC system 10 to produce significant values of DC current which may be required for certain applications.
  • the functionality of the subsystem sequence generator feeds a multiplexer that causes the modulated switch function “h+” applied to the M2LC subsystems 12 of the positive arm 14 to be “reassigned” at a period defined by the variable “rate”.
  • the switch function “reassignment” may be utilized with the M2LC subsystems 12 of the negative arm 16 instead of with the M2LC subsystems 12 of the positive arm 14 .
  • the “reassignment” shown in FIG. 5 is carried out so that after a certain number of periods have been completed, where the certain number of periods is equal to the number of M2LC subsystems 12 in the positive arm 14 of the output phase module, each of the values of the modulated switch functions will have been applied to each of the M2LC subsystems 12 in the positive arm 14 of the output phase module.
  • the “reassignment” may be implemented in a number of different ways. For example, according to various embodiments, if there are three M2LC subsystems 12 in the positive arm 14 of an output phase module, for a given period (e.g., period 1), the first value of the modulated switch function is applied to the first M2LC subsystem 12 , the second value of the modulated switch function is applied to the second M2LC subsystem 12 , and the third value of the modulated switch function is applied to the third M2LC subsystem 12 .
  • a given period e.g., period 1
  • the first value is applied to the second M2LC subsystem 12
  • the second value is applied to the third M2LC subsystem 12
  • the third value is applied to the first M2LC subsystem 12
  • the first value is applied to the third M2LC subsystem 12
  • the second value is applied to the first M2LC subsystem 12
  • the third value is applied to the second M2LC subsystem 12 .
  • the above-described sequence of reassignment may be referred to as a rotation.
  • a “reassignment” other than a rotation may be utilized. For example, if there are three M2LC subsystems 12 in the positive arm 14 of an output phase module, for a given period (e.g., period 1), the first value of the modulated switch function is applied to the first M2LC subsystem 12 , the second value of the modulated switch function is applied to the second M2LC subsystem 12 , and the third value of the modulated switch function is applied to the third M2LC subsystem 12 .
  • the next period e.g., period 2
  • the first value is applied to the third M2LC subsystem 12
  • the second value is applied to the first M2LC subsystem 12
  • the third value is applied to the second M2LC subsystem 12
  • the next period e.g., period 3
  • the first value is applied to the second M2LC subsystem 12
  • the second value is applied to the third M2LC subsystem 12
  • the third value is applied to the first M2LC subsystem 12 .
  • the system control module 20 may utilize other multi-level modulation control schemes to realize the switch function reassignment and the relative phase control described above.
  • the system control module 20 may utilize time averaged modulation, state space modulation, etc.
  • the system control module 20 may produce separate sets of existence functions, modulated switch functions, etc. for positive arms (or negative arms) of other output phase modules.
  • FIG. 6 illustrates a high level representation of a control system module 30 of the M2LC system 10 according to other embodiments. For purposes of clarity, only a portion of the M2LC system 10 is shown in FIG. 6 .
  • the control system module 30 of FIG. 6 is similar to the control system module 20 of FIG. 5 , but is different in that the control system module 30 of FIG. 6 includes the functionality of two subsystem sequence generators (one for the positive arm and one for the negative arm). In FIG. 6 , the “n” existence functions produced by the negative arm sequence generator are shifted 180° from the “n” existence functions produced by the positive arm sequence generator. Each subsystem sequence generator is communicably connected to a different multiplexer.
  • each arm reassignment event is spaced so as not to occur at the same time.
  • each arm reassignment event is spaced by a period “rate/2”.
  • This spacing may also be utilized for some versions of M2LC subsystem bypass which require that a non-operating switch function which is held in reserve for the bypass event is reassigned in its zero state but is still able to allow for the voltage balance functionality of the control system module 30 .
  • the value of the spacing between the arm reassignments may be other non-zero values other than period “rate/2”.
  • the system control module 30 may utilize other multi-level modulation control schemes to realize the switch function reassignment and the relative phase control described above.
  • the system control module 30 may utilize time averaged modulation, state space modulation, etc.
  • the system control module 30 may produce separate sets of existence functions, modulated switch functions, etc. for positive and negative arms of other output phase modules.
  • FIG. 7 illustrates a high level representation of a control system module 40 of the M2LC system 10 according to yet other embodiments. For purposes of clarity, only a portion of the M2LC system 10 is shown in FIG. 7 .
  • the control system module 40 of FIG. 7 is similar to the control system module 30 of FIG. 6 , but is different in that the control system module 40 of FIG. 7 includes the bypass control functionality.
  • each M2LC subsystem 12 may have a corresponding bypass switch (e.g., IGBT Bypass) connected across the two terminals of the M2LC subsystem 12 .
  • IGBT Bypass IGBT Bypass
  • the control system module 40 provides a unique way to implement M2LC subsystem bypass options using the M2LC inverter topology shown in FIG. 4 .
  • the bypass control operates to produce a constant “0” state in both the positive and negative arms of all three output phase modules depending on the number of redundant cell ranks to be added. For example, adding 1 rank to the positive and negative arms for minimum n+1 redundancy causes the control system module 40 to produce a constant “0” in the k th M2LC subsystem 12 of each arm.
  • the control system module 40 then reassigns this “0” amongst all the M2LC subsystems 12 so that all of the M2LC subsystems 12 on average can be charged balanced.
  • the faulted M2LC subsystem 12 Upon the actual failure of one M2LC subsystem 12 (for instance in the positive arm of phase A), the faulted M2LC subsystem 12 is forced into a physical “0” state by the bypass switch (IGBT bypass) and its loss of voltage over time would then be replaced by eliminating the reassigned “0” in that arm only. In this way, all other redundant M2LC subsystems 12 are available for use if an additional M2LC subsystem 12 would fail in the negative arm of phase A, and likewise in positive and negative arms of phases B and C.
  • M2LC subsystem bypass By performing M2LC subsystem bypass in the above-described manner, the detrimental affects of high ripple voltage at low frequencies are avoided. Additionally, any resulting losses are not significantly greater than the losses experienced with M2LC systems which do not include the M2LC subsystem bypass functionality and the resulting KVA rating of the M2LC system is the same as in the no bypass case.
  • the legend “h + n” represents the n th value of the modulated switch function “h + ” and the legend “h ⁇ n” represents the n th value of the modulated switch function “If”.
  • PWM Pulse Width Modulated
  • the system control module 40 may utilize other multi-level modulation control schemes to realize the switch function reassignment and the relative phase control described above.
  • the system control module 30 may utilize time averaged modulation, state space modulation, etc.
  • the system control module 40 may produce separate sets of existence functions, modulated switch functions, etc. for positive and negative arms of other output phase modules.
  • FIG. 8 illustrates various embodiments of a M2LC system 50 .
  • the M2LC system 50 of FIG. 8 is similar to the M2LC system 10 of FIG. 4 , but is different in that the M2LC system 50 of FIG. 8 includes a bypass device 52 connected to a three-level M2LC subsystem 54 of the M2LC system 50 .
  • the M2LC system 50 includes a plurality of M2LC subsystems 54 , and each M2LC subsystem 54 may have a corresponding bypass device 52 connected thereto.
  • the M2LC subsystem 54 includes a controller 56 , ballast resistors 58 , capacitors, switching devices and diodes.
  • the switching devices may be embodied as any suitable type of switching device.
  • the switching devices may be embodied as insulated gate bipolar transistors (IGBTs).
  • the controller 56 is electrically connected to a current transformer 60 .
  • the current transformer 60 supplies power to the controller 56
  • the controller 56 supplies power to the respective gate terminals of the switching devices.
  • the connections between the controller 56 and the gate terminals of the respective switching devices are not shown in FIG. 8 .
  • each M2LC subsystem 54 is electrically connected to a corresponding current transformer 60 , and the power supplied to a given M2LC subsystem 54 may thus be supplied via only a single corresponding current transformer 60 .
  • the controller 56 is also communicably connected to a higher level controller (e.g., a hub controller) via, for example, two optical fibers. For purposes of simplicity, the higher level controller is not shown in FIG. 8 .
  • the bypass device 52 includes two switching devices, and the two switching devices may be embodied as any suitable type of switching devices.
  • the two switching devices may be embodied as a packaged set of IGBT's or as individual IGBTs, and the IGBTs can be of the same voltage rating as the IGBT's included in the three-level M2LC subsystem 54 .
  • the use of individually controlled dual IGBT's allows for independent discharge of each of the dual storage capacitors if required as a result of failure in the three-level M2LC subsystems 54 by applying a midpoint resistor 62 to the center tap 64 of the storage capacitors.
  • the resistor 62 can be used to discharge each current path before the IGBT set is turned on in tandem to short circuit the three-level M2LC subsystem 54 .
  • the resistor 62 also serves to ensure the voltage sharing on each bypass IGBT with reference to the individual DC buses.
  • the controller 56 is electrically connected to the capacitors and the non-gate terminals of the switching devices indirectly via the ballast resistors 58 .
  • the ballast resistors 58 may be any suitable type of ballast resistors.
  • the ballast resistors 58 and the controller 56 collectively define a reference point “M”. With this configuration, the voltage at the reference point “M” can be different than the voltage at the center tap 64 of the storage capacitors, current is not conducted from the reference point “M” directly to the center tap 64 of the storage capacitors, and the high resistance nature of the ballast resistors 58 operates to prevent common mode current from flowing into the ground system of the controller 56 .
  • FIG. 9 illustrates a simplified representation of a pole of the M2LC system 10 of FIG. 4 .
  • the respective arms of a pole (Z) of the M2LC system 10 may be represented as respective resonant circuits having variable capacitance.
  • the arms of the M2LC pole are modulated so that the total switched capacitor voltages sum to the total DC link voltage Vdc, the modulation (h) ranges in value between “0” and “1”, and the respective resonant circuits can be reduced to a single LRC circuit since the two arm capacitances, which are each a function of (h), effectively combine to the constant value C which is the total arm capacitance.
  • system control module e.g., system control module 20 , system control module 30 , system control module 40 , etc.
  • Z effective impedance of the pole
  • the ability to cancel a majority of the M2LC subsystem capacitors fundamental current component depends on that pole's resonant frequency relative to the rate of the M2LC subsystems switching frequencies.
  • This impedance should be sufficiently low so that the capacitors can share charging current during each gate function reassignment, and it should also be sufficiently low so that the modulation can be controlled (e.g., by reducing the phase shift between gate switch functions) so that the fundamental current in each M2LC pole can be cancelled in part as normally happens with a two-level topology.
  • pole inductor or inductors
  • FIGS. 10 and 11 respectively illustrate the pole impedance and the capacitor voltage response of a M2LC pole of the M2LC system 10 of FIG. 4 when an inductive filter 18 of the M2LC system 10 has a first inductance value ( FIG. 10 ) and a second inductance value ( FIG. 11 ).
  • the circuit values shown in FIGS. 10 and 11 are representative of actual values which might be utilized in a 4.1 kv 1000 HP 3-phase variable frequency drive.
  • the first inductance value is an inductance value which is typically utilized in known M2LC systems.
  • the second inductance value is an inductance value which is utilized in M2LC systems which are controlled by the above-described system control module (e.g., system control module 20 , system control module 30 , system control module 40 , etc.).
  • the output current frequency (the operating frequency “fo”) is usually less than the resonant frequency “fr”, and the switching frequency “fsw” is usually greater than the resonant frequency “fr”.
  • the resonant frequency “fr” is sufficiently greater than the operating frequency “fo” and is also greater than the switching frequency “fsw”.
  • the inductance value of the pole inductor to be utilized with the control system modules described hereinabove may be approximately 40 to 50 times smaller than a pole inductor utilized in prior art systems.
  • the size, cost and loss associated with the pole inductor to be utilized with the control system modules described hereinabove are also significantly less than the size, cost and loss associated with the pole inductor utilized in prior art systems.
  • control system modules described herein in combination with the selection of pole filter impedance and resonance in relation to fundamental and switching frequencies, allow for voltage balance and reduced ripple voltage to be achieved without the need for complicated monitoring and control from the higher level controller (the hub control) of the M2LC system. It will also be appreciated that the control system modules described herein are capable of forcing charge balance operation of the DC link voltages under no load current and output voltage conditions and that the control system modules also allow for the generation of DC output current, ripple voltage control at low output frequencies and the generation of “zero” voltage cells for high redundancy.
  • control system modules described herein are achievable when the pole inductance placed between each arm (or the total inductance connected to output terminals of M2LC subsystems 12 ) is sufficiently low such that its resonance with the effective pole capacitance is sufficiently above both the switching and operating frequency of the M2LC subsystem 12 .
  • the system control modules described hereinabove are capable of solving the low output frequency ripple voltage issue associated with other M2LC topologies and greatly simplifying and improving the ability of the M2LC subsystems 12 to balance voltage under all output operating conditions.

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